Why software is an important factor in the performance of warehouse automation

Automation control software plays a critical role in the return on investment companies can realize through the use of warehouse automation. With the right software, companies can reduce their upfront investment without compromising future flexibility, enhance inventory management in ways that reduce costs, improve service to customers and improve day-to-day operating efficiency. This is why it has become essential to carefully evaluate software capabilities before selecting a warehouse automation solution.

Most companies generally understand that warehouse automation can increase storage density and reduce the labour required to fill orders. As a result, those factors tend to dominate the business case for automation. However, they don’t encompass the full value automation can deliver. Much of the added value that can be achieved is made possible by the software that controls the automation solution and integrates the automation into warehouse, supply chain and delivery processes.

How software enhances the business value of warehouse automation

Warehouse management systems (WMS) play a critical role in managing warehouse inventory, labour and costs. However, these systems are not able to control the operation of automation systems such as an automated storage and retrieval system (ASRS). For that, an automation control system (ACS) is required, and the right ACS can bring added value through bottom-up digitization from the shop floor.

It starts with capabilities that reduce the investment in automation by eliminating the need to oversize systems due to inefficient management. For example, it’s important to find software that uses algorithms to optimize ASRS management, reduce wait times and deliver pallets in the sequence required for efficient material flow. This allows right-sized solutions to deliver speed and performance that meet or exceed oversized ones.

Digitalization brings greater intelligence to inventory and order management. By enabling the precise tracking of item locations and movements, the ACS can virtually eliminate human errors like misplacement or miscounting, reducing stockouts and overstock. It also enables flexible and granular shelf-life management. Through intelligent inventory and order management, an ACS can calculate the remaining shelf life at delivery for each order, allowing product retrieval based on delivery times and customer priority.

In addition, digitalization improves the speed and predictability of order fulfilment by optimizing picking and routing based on order priority, inventory availability and resource capacity.

Through these capabilities, the right automation control software can strengthen the business case for automation by reducing capital investment, lowering inventory costs, improving order accuracy and enhancing customer service.

How software improves operations in automated warehouses

ACS software delivers day-to-day operational value by efficiently managing demand variability, supporting better decision-making and streamlining the response to events like product recalls.

Software capable of controlling all components of an automation solution – including the ASRS, conveyors, AGVs and palletizing systems – as well as manual processes can synchronize workflows and dynamically balance resources to eliminate bottlenecks during demand peaks. The visibility and analytics provided by the software also allow managers to effectively use warehouse data to improve operations, including monitoring key performance indicators in real time.

Certain software can also reduce the costs of a recall. For instance, the system could quickly locate impacted products, including those already shipped, based on batch, best-before date or other information.

Must-have capabilities for automation control software

Not every automation control platform delivers the same functionality. Look for:

■ Modular, preconfigured architecture: Integrates automation control, warehouse execution and management, with industry-specific preconfigurations.

■ Intelligent inventory and order management: Manages inventory based on batch, expiry or best-before dates and aligns with customer expectations.

■ Resource orchestration: Controls both automation and manual processes to avoid siloing.

■ Traceability and analytics: Supports detailed tracking and 3D visualization of warehouse operations.

■ Intuitive user interface: Easy to use, consistent and multilingual.

■ Maturity and security: Ensure a roadmap, secure development, global support and a standardized platform.